Brush preassembly construction

Abstract: To facilitate manufacture, the brush tufts (111) are fitted to flat sections (103) which are then bent to form the desired three-dimensional configuration of the sections (103). The final shape of the brush is maintained by connecting together locking portions (105, 108).

Description: This invention relates to the manufacture of brushware products and, preferably, to such products which are constructed of a single raw material so that the finished product may be recycled when it is no longer functional. The brushware product is intended to be constructed from a minimum of material and provide brush tufts radiating inwardly or outwardly from a curved surface. Many different types of brushes have been devised over the years from an original tree branch or shrub branch, and developing into wire-set, anchor-set, staple-set, twisted-in-wire and resin-set designs. These designs include both natural and synthetic filament materials. There was also developed a method of fusing like materials such as polypropylene monofilament into a molded section of polypropylene to form a basic brushware configuration. Many prior patents invented by John C. Lewis, Jr., the inventor herein, disclose different variations and improvements in this overall concept. Representative of such patents are U.S. Patents No. 3,604,043; 4,189,189; 4,291,431; 4,348,060; 4,690,277; and 4,693,519, the disclosures of which are hereby incorporated by reference. These patents in general disclose tufted fused brush construction and mat-like devices wherein synthetic tufts are fused to molded base sections. There is no disclosure, however, therein of a brush or broom construction which can be obtained from a flat mat projection of the resulting three-dimensional object. The patents do disclose methods for tufting articles which methods may he used to form the constructions of this invention. In U.S. Patent No. 5,114,214, there is described an effort to me a toothbrush having tufts set in brush sections which are separated by attenuation grooves. The patent describes a process for heating the grooves so that the brush sections may be bent to form a radial or other type of surface wherein each section is disposed at an angle to adjacent sections but each individual section is contained in a single plane. Also in U.S. Patents No. 5,224,763 and 4,988,146 there are described different means for forming a brush construction wherein the tuft end is melted and then set in a cavity of heat-softened material. In Patent No. 5,224,763, a collar is provided around the cavity which, in turn, is swaged to secure the tuft in the cavity. Also, in Patent No. 4,988,146, the cavity is heat softened and may be formed in a variety of different geometric designs. These patents, however, also do not describe the means for making a three-dimensional body from a flat sheet projection. In US-A-3643282, a cylindrical brush is formed by hooking together the ends of a tufted rectangular strip. In EP-A-524153, a cylindrical brush is formed by overlapping and joining together the ends of an elongate tufted strip. In US-A-3175865, curved tufted lengths are joined together by springs to form a complete ring with the tufts facing inwards. According to a first aspect of the present invention, there is provided a brush preassembly construction comprising: a sheet of material configured as a two-dimensional projection of a predetermined three-dimensional brush design, said design including a three-dimensional tufted surface, said sheet having a first surface on which are mounted a plurality of mutually spaced brush tufts disposed at preselected sites thereon, said tufts covering at least a portion of said sheet, said portion being configured as a two-dimensional projection of said three-dimensional tufted surface; and assembly means carried by said sheet for assembling said sheet into said three-dimensional brush design; characterized in that: said sheet includes at least two integrally-connected sections between which there is at least one gap having opposed side edges which are curved; and said assembly means is arranged to close said or each gap by joining together said opposed curved side edges thereof, so as to assemble said sheet into said three-dimensional brush design. The brush design of this invention may have tufts radiating inwardly or outwardly depending upon the desired result and is preferably made of polypropylene resin. While it is desired to use tufts of monofilaments and a sheet of the same material, it is possible to use dissimilar materials such as a polypropylene molded sheet having polyester monofilament fused tufts thereon. According to a second aspect of the present invention, there is provided a method for forming a three-dimensional hollow tufted construction, comprising the steps of: providing a sheet configured as a two-dimensional projection of said three-dimensional tufted construction, said construction including a three-dimensional surface, wherein said sheet includes at least two integrally-connected sections between which there is at least one gap having opposed side edges which are curved; mounting brush tufts on a first surface of said sheet at predetermined sites on said sections, which are configured as a two-dimensional projection of said three-dimensional surface; and closing said or each gap by joining together said opposed curved side edges thereof, so as to form said three-dimensional hollow tufted construction. Non-limiting embodiments of the present invention will now be described with reference to the accompanying drawings, in which:- Figure 1 is a top view of the unassembled one-plane molded handle/filament support member of a first embodiment of the invention before mounting tufts thereon; Figure 1A is a side view of the unassembled member of Figure 1; Figure 1B is a side view of the unassembled handle/filament support member of Figure 1 after fusing synthetic filament tufts thereon; Figure 2 is a side view of the fused handle/filament support member of Figure 1B after assembly; Figure 2A is a view den along lines 2A-2A of Figure 2; Figure 3 is a top view of the unassembled one-plane molded filament support member of a second embodiment of the invention before fusing; Figure 3A is a cross-sectional view taken along lines 3A-3A of Figure 3; Figure 3B is a cross-sectional view taken along lines 3B-3B of Figure 3; Figure 4 is an inside view of the assembled fused filament support member of Figure 3; Figure 5 is a cross-sectional view taken along lines 5-5 of Figure 4; Figure 6 is a view of an unassembled molded single-plane filament support member of a third embodiment of the invention prior to fusing; Figure 7 is a side view of the member of Figure 6 after assembly; Figure 8 is a cross-sectional view taken along lines 8-8 of Figure 7; Figure 9 is a view of an unassembled single-plane molded brush support member of a fourth embodiment of the invention; Figure 10 is a cross-sectional view taken along lines 10-10 of Figure 9 of the member of Figure 9 after assembly; Figure 11 is a top view of an unassembled single-plane molded brush tuft support member of a fifth embodiment of the invention; Figure 12 is a side view of the unfused and unassembled molded support member of Figure 11; Figure 13 is a cross-sectional view of the fused and assembled support member, taken along lines 13-13 of Figure 11; and Figure 14 is a perspective view of a brush device assembled using the support member of Figure 13. The brushware device 100' of the first embodiment of the invention is shown in Figure 2. The device is made by first molding a thin, flat, thermoplastic two-dimensional sheet 100 of Fig. 1 comprising a handle extension 102, hang-up hook 101, two configured filament accepting sections 103 radiating outward from handle 102 at point 109 with raised designated filament fusing bases 104. A gap G is defined between the two sections 103. The reference letter G is used in the Figures for all of the embodiments to denote the gap(s) between the sheet sections. The sheet 100 is up to 0.90mm (0.035 inches) thick and the bases 104 are 2.03 to 2.29mm (0.08 to 0.09 inches) thick including the thickness of the base sheet 100. An assembly tab means 105 is provided to accept the hole means 108 located on extensions 107 attached to each section 103 by means of a molded "living hinge" 110. The pre-brushware device sheet 100 of Fig. 1 generally has an overall length of "Z" with the handle section 102 being of a length designated by "X" while the configured sections 103 generally can have both shape and length of "Y". Fig. 1A illustrates the flatness and designated lengths of each section of the molded sheet 100 prior to picking and fusing filament to the raised base sections 104, while Fig. 1B shows the fused sheet 100 with filament tufts 111 as fused at the base at 112. By using the tufting process of the above Lewis patents, the fused sheet of Fig. 1B remains flat as shoes even with a base sheet 100 having a thickness of 0.90mm(0.035 inches). The attachment means 105 can be seen extending downward from the handle section 102. Also, handle section 102 can be molded so as to have a more substantial configuration 106, without sacrificing the overall generally thin configuration of sheet 100. Fig. 2 illustrates the actual brushware, in this case a toilet bowl brush 100', as created from sheet 100 with the extended fused filament sections 103 bent around in a manner as to allow the sections 107 with hole means 108 to be located onto assembly means 105, with the "living hinge" 110 flexed at 110 to allow assembly into said brushware 100'. Fig. 2A illustrates the three-dimensional view of the filament tufts 111 spread in a normal brush pattern as radiating from base 103 as taken through lines 2A-2A of Fig. 2. An alternative means of assembly could involve edges 109' of molded sheet 100 as shown in Fig. 1 which is brought together along its length and interconnects along said edge 109' to allow the two sections 103 to merge as shown in Fig. 2A. In either method of assembly, the resultant brushware 100' has a three dimensional shape that is impossible to manufacture on ordinary brush and broom equipment. Other most important features are the conservation of the starting raw materials, and the fact that the brushware is totally recyclable. Hygienic properties are imparted to this construction since there are no staple holes located on the brushware for bacteria to collect in, and a non-absorbing thermoplastic polymer is used so that no water or other chemical compounds can penetrate. The brushware article is completely bacteria, mold and/or mildew resistant. The thin nature of the design also allows the brushware item to dry completely after use in a liquid medium. The brushware is also dishwasher safe. It is possible to design a one-piece fused, cup-shaped internally tufted brushware device utilizing the instant invention. Fig. 4 illustrates a cup brush 200 having fused filament tufts 208 as fused directly to tuft receiving projections 206 (Fig. 3) at 206'. The brushware device 200 becomes an inverted tufted device by first utilizing the molded one-piece configuration having both configured filament accepting sections 200' and 201 integrally connected at 202' as shown in Fig. 3. Flat section 200' has a preconfigured top edge 203, while edges 202''', 204 and 205 possess edge connecting means in order to become attached to the edge 202 of filament accepting section 201. As shown in Fig. 4, the edges 204 and 205 form the means to fasten the circular tufted section 200' together to form the mat of inverted filament tufts 208. At the same time, the edges 202 and 202''' are joined together at 209 as shown in Figs. 3A, 3B and 5 by allowing the projection means 202 located at 202'' to engage slot 202'''. Fig. 5 is a cross-sectional view of the tufted brushware device as taken through lines C-C of Fig. 4, illustrating the position of the tufts which form a perfect cup-like working surface. The cup brushware device 200 can be held in one's hand simply by grasping the outer wall 200''. A golf ball brushware washing device 300 which would be held within a mechanical means, such means not shown, consists of a premolded and configured sheet 301 having integral connections 303 between repeating filament accepting sections 302 with pre-arranged filament designated areas 306, 306' and 306'' thereon as shown in Fig. 6. The sections 302 are molded in such manner as to have "living hinge" joints at 302', which allows the sections 302 to become a three dimensional configuration during assembly. Edges 304 and 304' become joined along the edge 305 during assembly as shown in Fig. 7. Fig. 8 illustrates the action the tufts 307 fused at 306, 306' and 306'' have on a golf ball 308 during the rotation of said ball 308 through the "C" shaped brushware device 300. Figs. 9 and 10 illustrate a reverse cup-type brushware device 411 where the molded flat configured sheet is comprised of two sections 400 and 401 interconnected integrally at position 402, said position 402 being a "living hinge". Instead of having raised or level filament locating areas, there are disposed "through holes" 408 which accept the picked and fused ends of filament tufts 410. As illustrated in Fig. 10, the fused filament ends 409 result in a fused mass of thermoplastic 409' which is cooled and mechanically conforms and attaches to the molded opening 408. Thus, different materials, i.e. polypropylene and polyester, may be employed for the molded flat configured sheet and filament tufts respectively. One must realize, though, that the resultant brushware 411 produced with two different raw materials cannot be recycled as one material. The resultant brushware 411 has the same type of edge means for bringing together the original configured sheet 400, and is held together by affixing edge means 403, 404, 405 and 406. Figs. 11 through 14 illustrate a modified handle cup brushware device 500' that can be obtained by molding a threaded means 509 integral with the original flat configured sheet sections 500 and 501 and then treating the fusing of filament tufts as previously described onto filament areas 509 thus forming filament tufts 511 fused at position 510. After fusing the pre-configured tufts onto sheet sections 500 and 501, the resulting unit is assembled by bringing together edge means 503, 504, 505 and 506. The non-cooperating edge 507 may be configured with any rim shape necessary to impart added strength to the resultant brushware unit. Fig. 14 illustrates the brushware device 500' having a wooden, metal or fiberglass handle. By configuring the two integrally joined filament sections 500 and 501, various slant degrees may be obtained in the resultant filament tufts, which would allow brushware to be designed to do a specific function. Obviously, many modifications and variations of the embodiments are possible in light of the above teachings. The device may be made from polypropylene molded resin and fused synthetic polypropylene monofilament as the preferred material; however, other synthetic resins such as polyesters, polystyrenes, polyamides and the like may be employed. Filament diameters and cross-sectional shapes may also be varied, with diameters ranging from 0.13 to 1.27mm (0.005 through 0.050 inches) and cross-sectional shapes from circular, "X", "Y" and other shapes, thus imparting different cleaning attributes within the mat structure. The molded base sectional members may have a circular shape as well as any polygonal shape so long as it is possible to configure a three-dimensional space to accept a brush configuration. Either the upper or lower side of the molded surface may contain rib or structural fin-like projections in order to reinforce tufted surfaces for ultimate strength without sacrificing the lightweight properties of the resultant brushware. There are unlimited brushware designs that can now be manufactured since there is no need to change the attitude or plane of the brush/broom block in order to affix the filament tufts thereon. Instantaneous picking and fusing of all the filament tufts in one plane and parallel filament arrangement prior to assembly into a three-dimensional brushware device can be achieved by practicing the instant invention. The tuft base is not limited to being produced by injection molding. Instead, the tuft base can be blow-molded. For example, a liquid applicator is blow molded and the side walls are wide apart at one location to define a liquid reservoir which may be gripped. The side walls touch or almost touch at another location to define a sheet-like tuft base. By changing the shape of the sheet-like tuft base during manufacture of the brush, it is possible to produce brushes having tuft bases with shapes which would otherwise be difficult to tuft. The final shape of the tuft base is maintained by connecting together portions of the brush preassembly, so that use of the brush will not bend the tuft base back to its original shape.

Claims: A brush preassembly construction comprising: a sheet (100, 301) of material configured as a two-dimensional projection of a predetermined three-dimensional brush design (100', 200, 300, 411, 500'), said design including a three-dimensional tufted surface, said sheet having a first surface on which are mounted a plurality of mutually spaced brush tufts (111, 208, 307, 410, 511) disposed at preselected sites thereon, said tufts covering at least a portion of said sheet, said portion being configured as a two-dimensional projection of said three-dimensional tufted surface; and assembly means (105, 108, 202, 202''', 403, 404, 503, 504) carried by said sheet for assembling said sheet into said three-dimensional brush design; characterized in that: said sheet includes at least two integrally-connected sections (103, 200', 201, 302, 400, 401, 500, 501) between which there is at least one gap (G) having opposed side edges (109', 202, 202''', 304, 304', 403, 404, 503, 504) which are curved; and said assembly means (105, 108, 202, 202''', 403, 404, 503, 504) is arranged to close said or each gap by joining together said opposed curved side edges thereof, so as to assemble said sheet into said three-dimensional brush design. The construction of claim 1, wherein said tufts (111, 208, 307, 410, 511) and sheet (100, 301) are of the same thermoplastic material. The construction of claim 1 or 2, wherein said first surface of said sheet has raised sites (104, 206) to which are fused prefused ends (112) of said tufts. The construction of any one of claims 1 to 3, wherein said assembly means includes a slot (202''') and a bead (202) provided on respective ones of said opposed curved side edges of said or each gap (G). The construction of any one of claims 1 to 3, wherein said assembly means includes a projection (105) molded on a surface of said sheet (100) and a hole (108) provided through each section (103) of said sheet for receiving said projection. A method for forming a three-dimensional hollow tufted construction (100', 200, 300, 411, 500'), comprising the steps of: providing a sheet (100, 301) configured as a two-dimensional projection of said three-dimensional tufted construction, said construction including a three-dimensional surface, wherein said sheet includes at least two integrally-connected sections (103, 200', 201, 302, 400, 401, 500, 501) between which there is at least one gap (G) having opposed side edges (109', 202, 202''', 304, 304', 403, 404, 503, 504) which are curved; mounting brush tufts (111, 208, 307, 410, 511) on a first surface of said sheet at predetermined sites (104, 206, 306, 408, 508) on said sections, which are configured as a two-dimensional projection of said three-dimensional surface; and closing said or each gap (G) by joining together said opposed curved side edges (109', 202, 202''', 304, 304', 403, 404, 503, 504) thereof, so as to form said three-dimensional hollow tufted construction. The method of claim 6, wherein in said construction said tufts (208, 307) are radially inwardly directed from said three-dimensional surface. The method of claim 7, wherein the outer surface (200'') of said construction functions as a handle portion. The method of claim 6, wherein in said construction said tufts (111, 410, 511) are radially outwardly directed from said three-dimensional surface. The method of any one of claims 6 to 9, wherein said opposed curved side edges of said or each gap (G) are joined by inserting a bead (202) provided on one of said edges in a slot (202''') provided on the other of said edges.

Inventors: LEWIS JOHN C, LEWIS, JOHN C.
Applicants: TUCEL INDUSTRIES, TUCEL INDUSTRIES, INC.
Application year: 1994
Main classification: A46B5
IPC codes: A46D3, A46B5, A46D9